Instrument panel with passenger airbag

ABSTRACT

An instrument panel includes a substrate having an outer surface and an inner surface, a covering, a foam layer between the outer surface and the covering, and a chute elongated to an end. The end is attached to the inner surface. The end includes a protrusion elongated along a perimeter of the end and extending through the substrate into the foam layer.

BACKGROUND

Vehicles are equipped with airbags. In the event of an impact, an inflator activates and provides inflation medium to the airbags, and the airbags pressurize and act as cushions for occupants during the impact. The airbags are located at various fixed positions in passenger cabins of vehicles. Vehicles typically include a driver airbag mounted in the steering wheel, a passenger airbag mounted in the instrument panel in a vehicle-forward direction from the front passenger seat, and side air curtains mounted in the roof rails.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a passenger cabin of a vehicle.

FIG. 2 is an exploded perspective view of an instrument panel of the passenger cabin of FIG. 1.

FIG. 3 is a cross-sectional view of the instrument panel of FIG. 2 with an airbag in an uninflated position.

FIG. 4 is a cross-sectional view of the instrument panel of FIG. 2 with the airbag in an inflated position.

DETAILED DESCRIPTION

An instrument panel includes a substrate having an outer surface and an inner surface, a covering, a foam layer between the outer surface and the covering, and a chute elongated to an end. The end is attached to the inner surface, and the end includes a protrusion elongated along a perimeter of the end and extending through the substrate into the foam layer.

The instrument panel may further include a housing including the chute and a door, and the door may at least partially cover the end of the chute and be adjacent the substrate. The housing may include a hinge connecting the door to the end of the chute. The protrusion and the hinge in combination may be elongated along substantially all the perimeter of the end of the chute.

The housing may be a single piece. The housing may include a flange extending outward from the chute. The door and the flange may be attached to the substrate. The door and the flange may be welded to the substrate.

The hinge may have an S-shaped cross-section.

The substrate may include a slot elongated along the perimeter of the end of the chute away from the hinge. The slot may be shaped to receive the protrusion.

The door may be attached to the substrate.

The protrusion may have a constant cross-section along the perimeter of the end of the chute. The cross-section of the protrusion may be wedge-shaped. The wedge-shape of the cross-section of the protrusion may have an angle less than 45°.

The chute may be welded to the substrate.

The instrument panel may further include an airbag disposed in the chute.

With reference to the Figures, an instrument panel 32 in a vehicle 30 includes a substrate 34 having an outer surface 36 and an inner surface 38, a covering 40, a foam layer 42 between the outer surface 36 and the covering 40, and a chute 44 elongated to an end 46. The end 46 is attached to the inner surface 38. The end 46 includes a protrusion 70 elongated along a perimeter of the end 46 and extending through the substrate 34 into the foam layer 42.

The instrument panel 32 may be a foam-in-place instrument panel, and the design of the instrument panel 32 allows for bottom-up installation of the chute 44. The chute 44 allows for a larger airbag 66, both laterally and longitudinally, than other designs while still deploying the airbag 66 sufficiently quickly and cleanly along a score line 94 of the covering 40. The instrument panel 32 reduces foam fragmentation, provides more consistent opening of the instrument panel 32, improves turtle necking, and allows multiple types of scoring techniques on the covering 40 because the protrusion 70 concentrates the force of the airbag 66 inflating on the foam layer 42 and the covering 40.

With reference to FIG. 1, the vehicle 30 includes a passenger cabin 47 to house occupants, if any, of the vehicle 30. The passenger cabin 47 includes a driver seat 48 and a passenger seat 50 disposed at a front of the passenger cabin 47 and one or more back seats 52 disposed behind the driver seat 48 and passenger seat 50. The passenger cabin 47 may also include third-row seats (not shown) at a rear of the passenger cabin 47. In FIG. 1, the driver seat 48 and passenger seat 50 are shown to be bucket seats, but the seats 48, 50, 52 may be other types. The position and orientation of the seats 48, 50, 52 and components thereof may be adjustable by an occupant.

The instrument panel 32 may be disposed at a forward end of the passenger cabin 47 and face toward the driver seat 48 and passenger seat 50. The instrument panel 32 may include vehicle controls, such as a steering wheel; gauges, dials, and information displays; heating and ventilation equipment; a radio and other electronics; etc. As described below, the instrument panel 32 may be a foam-in-place instrument panel, i.e., assembled by injecting the foam layer 42 between the substrate 34 and the covering 40.

With reference to FIGS. 2 and 3, the instrument panel 32 includes the substrate 34. The substrate 34 is elongated laterally, i.e., in a vehicle-crosswise-direction, across the passenger cabin 47 and curved along a longitudinal direction, i.e., a vehicle-forward direction. The outer surface 36 of the substrate 34 faces the passenger cabin 47, and the inner surface 38 faces away from the passenger cabin 47. The outer surface 36 is a concave side of the substrate 34, and the inner surface 38 is a convex side of the substrate 34. The substrate 34 may be a plastic and/or a composite, e.g., glass-filled polypropylene.

The substrate 34 includes a slot 54. The slot 54 may be U-shaped; more specifically, a portion of the slot 54 may be elongated laterally, and two portions may be elongated longitudinally, i.e., in a vehicle-forward direction, from ends of the laterally elongated portion of the slot 54. The slot 54 may have a constant width along its length. The substrate 34 may include a notch 92 elongated between ends of the slot 54. The notch 92 may be a weakened area, e.g., of less thickness than surrounding areas. The notch 92 may be formed as the substrate 34 is formed by injection molding, or the notch 92 may be formed by laser weakening a portion of the substrate 34 after formation.

The foam layer 42 is disposed between the substrate 34, e.g., the outer surface 36, and the covering 40. The foam layer 42 may be, e.g., polyurethane in a foamlike structure, i.e., with empty cells dispersed throughout.

The covering 40 extends over the outer surface 36 of the substrate 34 and over the foam layer 42. The covering 40 may be a material that is aesthetically pleasing to occupants, e.g., leather. The covering 40 may include the score line 94, i.e., a weakened area that will be opened by an airbag 66 inflating.

A housing 56 includes the chute 44, a door 58, a hinge 60 connecting the door 58 to the chute 44, and a flange 62. The housing 56 may be integral, i.e., may be a single piece, i.e., may be made of a single, uniform piece of material with no seams, joints, fasteners, or adhesives holding the housing 56 together. The housing 56 may be positioned in front of, i.e., in a vehicle-forward direction from, the passenger seat 50.

The chute 44 has a tubular shape that is elongated from a bottom panel 64 to the end 46. The chute 44 may have a rectangular cross-sectional shape, e.g., with rounded corners. The bottom panel 64 may be closed, and the end 46 may be open. An inside lateral cross-sectional width of the chute 44 may be approximately equal to a lateral length of the slot 54, and an inside longitudinal cross-sectional width of the chute 44 may be approximately equal to a longitudinal length of the slot 54. An outside lateral cross-sectional width of the chute 44 may be longer than the lateral length of the slot 54, and an outside longitudinal cross-sectional width of the chute 44 may be longer than the longitudinal length of the slot 54. Moreover, the chute 44 may include stiffeners 90 elongated from the bottom panel 64 to the end 46, and the stiffeners 90 extend further outside the lateral and longitudinal length of the slot 54. At least some of a perimeter of the end 46 of the chute 44 is elongated along the slot 54. The slot 54, e.g., an entire length of the slot 54, is elongated along the perimeter of the end 46 of the chute 44. The slot 54 may be elongated along the perimeter of the end 46 of the chute 44 away from the hinge 60.

The airbag 66 is disposed in the chute 44. The airbag 66 may be a passenger airbag. The airbag 66 may be sized to cushion an occupant of the passenger seat 50 during a frontal impact to the vehicle 30. The airbag 66 is inflatable from an uninflated position, as shown in FIG. 3, to an inflated position, as shown in FIG. 4.

The flange 62 extends outward from the chute 44. Specifically, the flange 62 extends outward from the perimeter of the end 46. The flange 62 faces the substrate 34 and may be shaped to conform to the substrate 34.

The door 58 at least partially covers the end 46 of the chute 44. The door 58 is adjacent to the substrate 34. One side of the door 58 faces the substrate 34, and the other side of the door 58 faces the airbag 66.

The hinge 60 connects the door 58 to the end 46 of the chute 44. The hinge 60 is elongated along some of the perimeter of the end 46 of the chute 44; e.g., the hinge 60 may be elongated along a section of the perimeter of the end 46 of the chute 44 along which the slot 54 is not elongated. The hinge 60 may be elongated along the notch 92. The hinge 60 may be connected to a vehicle-forward edge of the door 58. The hinge 60 has an S-shaped cross-section, i.e., a cross-section following at least two curves turning opposite directions, i.e., a cross-section following at least two curves with concave sides facing opposite directions.

The door 58 and the end 46 of the chute 44 define a gap 68 therebetween. The gap 68 may be elongated along the perimeter of the end 46 of the chute 44. The gap 68 may be elongated along substantially all the slot 54. The hinge 60 and the gap 68 in combination may be elongated along substantially all the perimeter of the end 46 of the chute 44. The gap 68 may have a substantially constant width along its length.

The housing 56 is attached to the substrate 34. For example, the flange 62 and/or the door 58 are attached to the inner surface 38 of the substrate 34. The flange 62 and/or the door 58 may be directly attached to the substrate 34 in any suitable manner, e.g., adhesion, fastening, welding, etc. For example, the flange 62 and/or the door 58 may be friction-welded to the inner surface 38 of the substrate 34, i.e., may have a boundary between the substrate 34 and the flange 62 and/or between the substrate 34 and the door 58 melted together so that the molecules intermingle across the boundary. The flange 62 and/or the door 58 may include ribs 88 at which the friction welding has occurred. The chute 44 may be attached, e.g., friction-welded, to the substrate 34 via the flange 62 and/or the door 58.

The end 46 of the chute 44 includes the protrusion 70 elongated along the perimeter of the end 46. The protrusion 70 extends through the substrate 34, e.g., through the slot 54, and into the foam layer 42, i.e., at least partially through the foam layer 42. The protrusion 70 is elongated along the gap 68 and along the slot 54, and the slot 54 is shaped to receive the protrusion 70.

The protrusion 70 has a constant cross-section along its length, i.e., along the perimeter of the end 46 of the chute 44. The cross-section of the protrusion 70 has a wedge shape terminating at an angle pointed into the foam layer 42. The angle may be an acute angle; more specifically, the angle may be less than 45°. The angle helps to concentrate the force of the airbag 66 during inflation.

With reference to FIG. 4, in the event of, e.g., an impact to the vehicle 30, the airbag 66 inflates. As the airbag 66 inflates, the airbag 66 pushes against the chute 44 and the door 58. The stiffness of the chute 44 concentrates the force of the airbag 66 against the door 58. The S-shaped cross-section of the hinge 60 allows the hinge 60 to bend and the door 58 to rotate open relative to the chute 44. The slot 54 and the protrusion 70 define a weak point for the force of the airbag 66 to concentrate. The door 58 breaks through the foam layer 42 and the covering 40, and the airbag 66 expands in front of an occupant of the passenger seat 50. The airbag 66 cushions the occupant and may reduce injury.

The disclosure has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present disclosure are possible in light of the above teachings, and the disclosure may be practiced otherwise than as specifically described. 

What is claimed is:
 1. An instrument panel comprising: a substrate having an outer surface and an inner surface; a covering; a foam layer between the outer surface and the covering; and a chute elongated to an end, the end attached to the inner surface, the end including a protrusion elongated along a perimeter of the end and extending through the substrate into the foam layer.
 2. The instrument panel of claim 1, further comprising a housing including the chute and a door, the door at least partially covering the end of the chute and being adjacent the substrate.
 3. The instrument panel of claim 2, wherein the housing includes a hinge connecting the door to the end of the chute.
 4. The instrument panel of claim 3, wherein the protrusion and the hinge in combination are elongated along substantially all the perimeter of the end of the chute.
 5. The instrument panel of claim 3, wherein the housing is a single piece.
 6. The instrument panel of claim 5, wherein the housing includes a flange extending outward from the chute.
 7. The instrument panel of claim 6, wherein the door and the flange are attached to the substrate.
 8. The instrument panel of claim 7, wherein the door and the flange are welded to the substrate.
 9. The instrument panel of claim 3, wherein the hinge has an S-shaped cross-section.
 10. The instrument panel of claim 3, wherein the substrate includes a slot elongated along the perimeter of the end of the chute away from the hinge.
 11. The instrument panel of claim 10, wherein the slot is shaped to receive the protrusion.
 12. The instrument panel of claim 2, wherein the door is attached to the substrate.
 13. The instrument panel of claim 1, wherein the protrusion has a constant cross-section along the perimeter of the end of the chute.
 14. The instrument panel of claim 13, wherein the cross-section of the protrusion is wedge-shaped.
 15. The instrument panel of claim 14, wherein the wedge-shape of the cross-section of the protrusion has an angle less than 45°.
 16. The instrument panel of claim 1, wherein the chute is welded to the substrate.
 17. The instrument panel of claim 1, further comprising an airbag disposed in the chute. 